Power tool including a battery pack isolation system

ABSTRACT

A power tool includes a housing, a motor positioned substantially within the housing, a drive mechanism supported by the housing and coupled to the motor, a battery pack electrically coupled to the motor, and an isolation system. The isolation system includes an interface member positioned substantially within the housing. The interface member receives a portion of the battery pack to electrically couple the battery pack to the motor. The isolation system also includes a plurality of isolators coupled between the housing and the interface member to isolate the battery pack from the housing during operation of the power tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/408,602, filed Aug. 23, 2021, which is a continuation of U.S. patentapplication Ser. No. 16/287,807, filed Feb. 27, 2019, now U.S. Pat. No.11,117,234, which is a continuation of U.S. patent application Ser. No.14/270,547, filed May 6, 2014, now U.S. Pat. No. 10,232,479, whichclaims priority to U.S. Provisional Patent Application No. 61/820,032,filed May 6, 2013, the entire contents of each are incorporated hereinby reference.

BACKGROUND

The present invention relates to power tools and, more particularly, tobattery pack isolation systems for power tools.

Power tools (e.g., reciprocating saw, drill, circular saw, jigsaw, etc.)generate vibrational forces during operation of the power tool. Bynature, some power tools (e.g., reciprocating saws) generate moreaggressive vibrational forces than other power tools (e.g., drills). Itis advantageous to isolate the vibrational forces within the power toolsso that the vibration forces do not propagate to a battery pack thatpowers the power tools. Excess vibrational forces exerted on the batterypack can limit the life cycle of the battery pack.

SUMMARY

In one embodiment, the invention provides a power tool including ahousing, a motor positioned substantially within the housing, a drivemechanism supported by the housing and coupled to the motor, a batterypack electrically coupled to the motor, and an isolation system. Theisolation system includes an interface member positioned substantiallywithin the housing. The interface member receives a portion of thebattery pack to electrically couple the battery pack to the motor. Theisolation system also includes a plurality of isolators coupled betweenthe housing and the interface member to isolate the battery pack fromthe housing during operation of the power tool.

In another embodiment, the invention provides an isolation system for apower tool. The power tool includes a housing, a motor positionedsubstantially within the housing, a drive mechanism supported by thehousing and coupled to the motor, and a battery pack electricallycoupled to the motor. The isolation system includes an interface memberpositioned substantially within the housing. The interface member isconfigured to receive a portion of the battery pack to electricallycouple the battery pack to the motor. The isolation system also includesa plurality of isolators coupled between the housing and the interfacemember to isolate the battery pack from the housing during operation ofthe power tool.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a power tool including a battery packisolation system.

FIG. 2 is a side view of the power tool with a portion of a housingremoved.

FIG. 3 is a perspective view of a battery pack of the power tool.

FIG. 4 is an end perspective view of a portion of the power tool withoutthe battery pack.

FIG. 5 is an exploded perspective view of a portion of the power toolincluding the battery pack isolation system.

FIG. 6 is a perspective view of the battery pack isolation system.

FIG. 7 is a side view of an isolator of the battery pack isolationsystem.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a power tool 10. The illustrated power tool 10is a multi-tool operable to oscillate a cutting blade, a scraping blade,a sanding sheet, and the like. In other embodiments, the power tool 10may be, for example, a reciprocating saw, a drill, a circular saw, ajigsaw, a band saw, a screwdriver, an angle or straight grinder, ahammer drill, or an impact wrench. In such embodiments, the power tool10 may be operable to oscillate, rotate, reciprocate, or otherwise driveother types of output elements such as drill bits, saw blades, and thelike.

The illustrated power tool 10 includes a housing 14, a motor 18, a drivemechanism 22, an output element 26, and a battery pack 30. The housing14 includes two clamshell halves 34A, 34B that are connected together toenclose the motor 18 and the drive mechanism 22. When connectedtogether, the clamshell halves 34A, 34B define a grip portion 38 and abattery support portion 42 of the housing 14. The grip portion 38 isconfigured to be grasped by a user during operation of the power tool10. The battery support portion 42 is configured to indirectly supportthe battery pack 30 on the housing 14, as further described below.

As shown in FIG. 2 , the motor 18 and the drive mechanism 22 arepositioned substantially within the housing 14 in front of the gripportion 38. In some embodiments, the drive mechanism 22 is positionedwithin a gear case inside of and/or supported by the housing 14. Thedrive mechanism 22 is coupled to the motor 18 to be driven by the motor18. When energized, the motor 18 drives the drive mechanism 22 tooscillate the output element 26.

The output element 26 is coupled to an output shaft or spindle (notshown) of the drive mechanism 22. The illustrated output element 26 islocated at an opposite end of the housing 14 from the battery pack 30,but may alternatively be located in other locations on the housing 14relative to the battery pack 30. In the illustrated embodiment, theoutput element 26 is a cutting blade that is oscillated during operationof the power tool 10. In other embodiments, the output element 26 may bea different type of element (e.g., a scraping blade, a sanding sheet,etc.) and/or may be driven in a different manner (e.g., rotated,reciprocated, etc.) by the drive mechanism 22.

The battery pack 30 is supported at the battery support portion 42 ofthe housing 14 and electrically coupled to the motor 18. Duringoperation of the power tool 10, the battery pack 30 supplies power tothe motor 18 to energize the motor 18. The illustrated battery pack 30is an 18 volt Li-ion power tool battery pack. In other embodiments, thebattery pack 30 may have different voltages (e.g., 12 volts, 14.4 volts,28 volts, etc.) and/or chemistries (e.g., NiCd, etc.).

As shown in FIG. 3 , the battery pack 30 includes a connection portion46 and a securing mechanism 50. In the illustrated embodiment, theconnection portion 46 includes two parallel, spaced apart rails 54 suchthat the battery pack 30 is a slide-on-style battery pack. In otherembodiments, the battery pack 30 may be a tower-style battery pack thatis at least partially inserted into the housing 14 of the power tool 10.The connection portion 46 also includes terminals 58 to electricallyconnect the battery pack 30 to a motor or other device. The securingmechanism 50 includes two latches 62 (only one of which is shown) forreleasably securing the battery pack 30 to the power tool 10. Thelatches 62 extend from the connection portion 46 adjacent the rails 54.An actuator 66 is coupled to each latch 62 to facilitate manuallyoperating (e.g., moving) the latches 62 relative to the connectionportion 46.

As shown in FIGS. 4-6 , the power tool 10 also includes an isolationsystem 70 to connect the battery pack 30 to the housing 14. Theisolation system 70 mechanically isolates the battery pack 30 from thehousing 14 during operation of the power tool 10. That is, in contrastto a damping system that reduces the magnitude of vibrations that aretransferred to a battery pack, the isolation system 70 isolates thebattery pack 30 from at least some vibrations caused by the motor 18 andthe drive mechanism 22. The overall transfer of vibrations, particularlyhigh frequency vibrations, to the battery pack 30 during operation ofthe power tool 10 is greatly reduced. The isolation system 70 isconfigured to allow the housing 14 to move in six degrees of freedom(i.e., forward-backward, up-down, and side-to-side) relative to thebattery pack 30 such that certain frequencies of vibrations are nottransferred to the battery pack 30, regardless of the direction of thatparticular vibration.

The illustrated isolation system 70 includes an interface member 74,isolators 78, and a terminal block 82. As shown in FIGS. 4 and 5 , theinterface member 74 is captured between the two clamshell halves 34A,34B of the housing 14. The illustrated interface member 74 includes twoparallel, spaced apart rails 86 that correspond to the rails 54 (FIG. 3) of the battery pack 30. The interface rails 86 are configured toengage the battery pack rails 54 to connect and support the battery pack30 on the housing 14. The interface member 74 also defines two recesses90 adjacent the rails 86. The recesses 90 are configured to receive thelatches 62 (FIG. 3 ) of the battery pack 30 to releasably secure thebattery pack 30 to the interface member 74. In other embodiments, theinterface member 74 may be configured to receive a tower-style batterypack and/or battery packs having different securing mechanisms.

The interface member 74 also includes two elastomeric members 94positioned adjacent the rails 86 on either side of the terminal block82. The elastomeric members 94 are positioned adjacent opposite ends ofthe rails 86 from the recesses 90 that receive the battery pack latches62. Stated another way, the elastomeric members 94 are position at aclosed end of the interface member 74 opposite from an open end of theinterface member 74 that receives the battery pack 30. The illustratedelastomeric members 94 are rubber cylinders that fit withincorresponding notches in the interface member 74. The elastomericmembers 94 engage the connection portion 46 (FIG. 3 ) of the batterypack 30 when the battery pack 30 is connected to the interface member74. In particular, the elastomeric members 94 take up clearances ortolerances between the battery pack 30 and the interface member 74 topreload the latches 62 of the battery pack 30. Such an arrangementcreates a relatively tight engagement between the battery pack 30 andthe interface member 74 such that the battery pack 30 and the interfacemember 74 do not move (e.g., vibrate) relative to each other. In someembodiments, the elastomeric members 94 may be omitted.

As shown in FIG. 5 , the isolators 78 are positioned between theinterface member 74 and the housing 14 to isolate the interface member74, and thereby the battery pack 30, from the housing 14. In theillustrated embodiment, the isolation system 70 includes six isolators78. In other embodiments, the isolation system 70 may include fewer ormore isolators 78. Each isolator 78 is a generally annular member and iscomposed of an elastomeric or rubber material, such as polyurethane. Inother embodiments, the isolators 78 may have other shapes andconfigurations and/or may be composed of other suitable materials.

As shown in FIGS. 5 and 6 , the isolators 78 are positioned on posts 98,102 that extend from the interface member 74 and are received inopenings 106 formed in the housing 14. The illustrated interface member74 includes six posts 98 extending from opposing sidewalls 110A, 110B ofthe member 74, with three posts 98 extending from each sidewall 110A,110B. In the illustrated embodiment, isolators 78 are only positioned ontwo of the three posts 98 on each sidewall 110A, 110B, although in otherembodiments an isolator 78 may be positioned on every post 98. Theinterface member 74 also includes an upper projection 114 from which twoadditional posts 102 extend. The upper projection 114 is located halfwaybetween the opposing sidewalls 110A, 110B and extends perpendicularlyfrom an upper surface 118 (FIG. 6 ) of the interface member 74. In otherembodiments, the isolators 78 may be positioned on posts that extendfrom the housing 14 and received in openings formed in the interfacemember 74. The isolators 78 connect the interface member 74 to thehousing 14 such that the interface member 74 does not directly contactthe housing 14. As such, the interface member 74 and the battery pack 30are indirectly supported on the battery support portion 42 of thehousing 14 through the isolators 78.

FIG. 7 illustrates one of the isolators 78 in more detail. Theillustrated isolator 78 has a double-taper design. That is, the isolator78 tapers from its mid portion 122 toward a central longitudinal axis126 of the isolator 78. The isolator 78 thereby decreases in diameterfrom the mid portion 122 to both outer faces 130A, 130B (i.e., thediameter at the mid portion 122 of the isolator 78 is greater than thediameter at either outer face 130A, 130B of the isolator 78). Thedouble-taper design provides clearance for the isolator 78 to deflectand deform when the isolator 78 is compressed during operation of thepower tool 10 (e.g., when the housing 14 vibrates relative to theinterface member 74 and pushes against the isolator 78).

Referring back to FIGS. 4 and 5 , the terminal block 82 is mounted tothe interface member 74 between the rails 86. The illustrated terminalbock 82 is a separate piece from the interface member 74, but issupported by the interface member 74. In some embodiments, a biasingmember (e.g., a coil spring) may be positioned between the terminalblock 82 and the interface member 74 to help clamp the terminal block 82within the member 74. In other embodiments, the terminal block 82 may beintegrated into the interface member 74 such that the terminal block 82and the interface member 74 are a single piece.

The terminal block 82 includes electrical contacts that engage theterminals 58 (FIG. 3 ) of the battery pack 30 when the battery pack 30is connected to the interface member 74. The terminal block 82 iselectrically coupled to the motor 18 to provide power from the batterypack 30 to the motor 18. Since the terminal block 82 is directly mountedto the interface member 74 and not to the housing 14, the terminal block82 is also isolated from the housing 14 through the isolators 78 suchthat vibrations of the power tool 10 are not transferred to the batterypack 30 through the terminal block 82.

The isolation system 70 mechanically isolates the battery pack 30 fromthe housing 14 of the power tool 10 such that vibrations from the motor18 and the drive mechanism 22 are not transferred to the battery pack 30during operation of the power tool 10. Depending on the particular typeof power tool, the isolation system 70 may be configured to isolate thebattery pack 30 from different frequencies, or ranges of frequencies, ofvibrations. For example, the spring rate (e.g., material, shape, etc.)of the isolators 78 may be varied to isolate specific operationalfrequencies for particular types of power tools. In addition, the shapeof each isolator 78 may be changed to vary spring rate, dampeningproperties, and/or abrasion resistance.

Although the invention has been described with reference to certainpreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects of the invention.For example, in further embodiments, the battery pack isolation system70 may be used with other types of electrical devices that vibrateduring operation, such as vacuum cleaners, outdoor power equipment(e.g., blowers, chain saws, edgers, trimmers, lawn mowers, etc.), orvehicles (e.g., automobiles, motorcycles, scooters, bicycles, etc.).

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A power tool comprising: a housing including afirst portion and a second portion coupled to the first portion; a motorpositioned substantially within the housing between the first portionand the second portion; a drive mechanism supported within the housingbetween the first portion and the second portion, the drive mechanismcoupled to the motor; and an isolation system including an interfacemember configured to removably receive a portion of the battery pack toelectrically couple the battery pack to the motor, the interface memberhaving opposing sidewalls, a plurality of posts extending from thesidewalls of the interface member, the posts captured between the firstportion and the second portion, and elastomeric material adjacent theposts to isolate the battery pack from the housing during operation ofthe power tool.
 2. The power tool of claim 1, wherein each of theopposing sidewalls includes a first surface and a second surfaceopposite the first surface, the elastomeric material being locatedbetween the first surface of each of the opposing sidewalls and an innersurface of the first portion and the second portion, and each of thesecond surfaces having a rail configured to configured to slidablyreceive the battery pack.
 3. The power tool of claim 2, whereinelectrical contacts are supported by the interface member, theelectrical contacts configured to engage mating terminals of the batterypack.
 4. The power tool of claim 1, wherein electrical contacts aresupported by the interface member, the electrical contacts configured toengage mating terminals of the battery pack.
 5. The power tool of claim1, wherein a grip is formed by the first portion and the second portionand a battery support is portion formed by the first portion and thesecond portion, and wherein the interface member positionedsubstantially within the battery support portion.
 6. A power toolcomprising: a housing including a grip and a battery support portionintegrally formed with the grip; a motor positioned substantially withinthe housing; a drive mechanism supported within the housing, the drivemechanism coupled to the motor; and an isolation system including aninterface member positioned substantially within the battery supportportion and configured to removably receive a portion of the batterypack to electrically couple the battery pack to the motor, the interfacemember including two parallel, spaced apart rails configured to slidablyreceive the battery pack, and an isolator coupled between the housingand the interface member to isolate the battery pack from the housingduring operation of the power tool.
 7. The power tool of claim 6,wherein the interface member includes opposing sidewalls and an upperwall connecting the opposing sidewalls, and wherein the isolator islocated between one of the sidewalls and an inner surface of the batterysupport portion.
 8. The power tool of claim 6, wherein electricalcontacts are supported by the interface member, the electrical contactsconfigured to engage mating terminals of the battery pack.
 9. The powertool of claim 6, wherein the interface member includes opposingsidewalls and an upper wall connecting the opposing sidewalls, each ofthe opposing sidewalls including a first surface and a second surfaceopposite the first surface, the isolator being located between the firstsurface of one of the sidewalls and an inner surface of the batterysupport portion, and each of the second surfaces having one of therails.
 10. The power tool of claim 9, wherein electrical contacts aresupported by the interface member, the electrical contacts configured toengage mating terminals of the battery pack.
 11. The power tool of claim9, wherein the isolator is a first isolator and the inner surface of thebattery support portion is a first inner surface, and further comprisinga second isolator located between the first surface of the other of thesidewalls and a second inner surface of the battery support portion. 12.The power tool of claim 11, further comprising a third isolator beinglocated between the upper wall and another inner surface of the housing.13. A power tool comprising: a housing including a first portion and asecond portion coupled to the first portion, the housing defining a gripand a battery support portion; a motor positioned substantially withinthe housing between the first portion and the second portion; a drivemechanism supported within the housing between the first portion and thesecond portion, the drive mechanism coupled to the motor; and anisolation system including an interface member positioned substantiallywithin the housing between the first portion and the second portion, theinterface member including two parallel, spaced apart rails configuredto slidably receive the battery pack and electrical contacts configuredto electrically couple the battery pack to the motor, and an isolatorcoupled between the housing and the interface member to isolate thebattery pack from the housing during operation of the power tool. 14.The power tool of claim 13, wherein the interface member includesopposing sidewalls and an upper wall connecting the opposing sidewalls,and wherein the isolator is located between one of the sidewalls and thehousing.
 15. The power tool of claim 13, wherein the interface memberincludes opposing sidewalls and an upper wall connecting the opposingsidewalls, each of the opposing sidewalls including a first surface anda second surface opposite the first surface, the isolator being locatedbetween the first surface of one of the sidewalls and an inner surfaceof one of the first portion and the second portion, and each of thesecond surfaces having one of the rails.
 16. The power tool of claim 15,wherein the isolator is a first isolator and the inner surface of thehousing is a first inner surface, and further comprising a secondisolator located between the first surface of the other of the sidewallsand a second inner surface of the other of the first portion or thesecond portion.
 17. The power tool of claim 16, further comprising athird isolator located between the upper wall and one of the first innersurface and the second inner surface.
 18. The power tool of claim 15,wherein a plane is defined between the first portion and the secondportion, the plane bisecting the housing, the interface member includesopposing sidewalls and an upper wall connecting the opposing sidewalls,each of the opposing sidewalls including a first surface and a secondsurface opposite the first surface, the first surface of one of theopposing sidewalls is spaced apart from an inner surface of the firstportion in a direction toward the plane and the first surface of theother of the opposing sidewalls is spaced part from the inner surface ofthe second portion in a direction toward the plane, the isolator ispositioned between the first surface of one of the opposing sidewallsand the inner surface of the housing, and the second surface of each ofthe sidewalls defines one of the rails.
 19. The power tool of claim 15,wherein the grip is formed by the first portion and the second portionand the battery support is portion formed by the first portion and thesecond portion, and wherein the interface member positionedsubstantially within the battery support portion.